INSTALLATION MANUAL FOR. Mud Hog System II & System III 2-Speed Rear Wheel Drive FOR JOHN DEERE 9960, 9965 & 9970 COTTON PICKERS

Transcription

1 INSTALLATION MANUAL FOR Mud Hog System II & System III 2-Speed Rear Wheel Drive FOR JOHN DEERE 9960, 9965 & 9970 COTTON PICKERS Mud Hog Model Numbers Tread Center MH System & 9970 JD47601 JD II JD47602 JD II JD III JD III TUTHILL Drive Systems Brookston Indiana USA Revised 8/2010 P.N

2 Instructions and Specifications INTRODUCTION This manual provides instructions for installing the Mud Hog Drive System on hydrostatic machines. Various machine options such as rear axle width and front tire size affect Mud Hog adaptation. These differences are specifically referred to in these instructions. Always follow the instructions which refer to the exact option configuration on the machine being converted. A complete pictorial breakdown of all the individual parts in the Mud Hog Drive System can be found in the Mud Hog Parts Catalog. Refer to this catalog for proper identification of parts required for service. GENERAL The terms right and left in these instructions are the same as the operators right and left hand when positioned in the operator s seat facing forward. IMPORTANT: Cleanliness is essential when installing or servicing hydraulic components. When making hydraulic connections, areas surrounding the connection should be steam cleaned or washed with solvent so that contamination will not enter the system. Always keep hoses and connectors and ports suitably capped or covered to keep contamination out of the system. CAUTION: Make sure that system pressure is relieved before disconnecting any lines or connections. Pressurized fluid escaping from the system can cause serious personal injury. TORQUE SPECIFICATIONS RECOMMENDED FOR USE WITH Mud Hog FASTENERS Recheck all bolt & nut torque after 1 hour s use and again after first day of use. Periodically check tightness every 100 hours of use thereafter. Note: bolts that require Loctite should not be re-tightened once Loctite has had time to cure. Note: When using original equipment fasteners, adhere to manufacturers recommended specifications. GRADE 8 (GRADE 10.9 METRIC) BOLTS AND GRADE C LOCKNUTS SIZE BOLT TORQUE[1] LOCKNUT TORQUE[2] (S.A.E.) (ft.lbs.) (ft.lbs.) 1/ / / / / / / / / M M M HYDRAULIC FITTINGS, HOSE ENDS, TUBE NUTS DASH SIZE THREAD SIZE TORQUE[3] (S.A.E.) (S.A.E.) (ft.lbs.) -4 7/ / / / / / [1] Torque to be applied to Grade 8 bolts. [2] Torque to be applied to Grade C locknuts. [3] Torque to be applied to S.A.E. straight thread O-Ring Boss (ORB) fittings/locknuts and 37 degree flared type (J.I.C.) fittings/hose ends and tube nuts. NOTE: Mud Hog and Equa-Trac are registered trademarks of Tuthill Transport Technologies. B

3 ! Safety Procedures 1) READ THESE PROCEDURES COMPLETELY. Make sure you fully understand all controls BEFORE operating the system. 2) The safety information given does not replace safety codes, insurance needs, or federal, state, and local laws. 3) Standard safety procedures should be observed and practiced when operating or servicing the Mud Hog system. CAUTION should be practiced at all times. 4) All components MUST be securely and correctly mounted and connected BEFORE operating the system. 5) In the event of any malfunction in the system, the Mud Hog should be shut OFF immediately and not restarted until the machine is correctly serviced. 6) When raising the machine, make sure that a dependable left device is used to adequate capacity. Use suitable jack stands to support machine. Apply PARK or EMERGENCY BRAKE and block the front wheels to prevent the machine from rolling. 7) DANGER Escaping fluid under pressure can have sufficient force to penetrate the skin, causing serious personal injury. Fluid escaping from a small hole can be almost invisible. Use a piece of cardboard or wood rather than your hands, to search for suspected leaks. 8) DO NOT extend the axles beyond the distance stated in the instructions. 9) DO NOT alter axles in ANY manner alterations may reduce strength resulting in possible damage or personal injury. 10) DO NOT alter any component of the Mud Hog system. Unauthorized modification may result in possible damage or personal injury. 11) DANGER Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious bodily injury. DO NOT attempt to mount a tire unless you have the proper equipment and experience to perform the job safely. 12) WARNING Decals MUST be obeyed completely to prevent possible damage or injury. If decals are destroyed, lost damaged or cannot be read, replace immediately. 13) WARNING Any damaged hi-pressure hose should be replaced with a comparable 4-wire braid hose (DO NOT use a 2 or 3-wire braid hose). A

4 MUD-HOG SYSTEM IDENTIFICATION This manual covers both System II and System III MUD-HOG kits. The difference between Sys.II and Sys.III is wheel motor displacement. The Sys.II wheel motors have 57 cubic inches and the Sys.III wheel motors are two speed motors with displacements of 38 and 76 cubic inches. The number of hoses connected to the wheel motors will tell you which system your MUD-HOG kit is. A Sys.II has 4 hoses per motor and a Sys.III has 5 hoses per motor. Several sections in this manual will refer to either Sys.II or Sys.III. Sections that do not specify one or the other system are for both systems. SYS.III 2-SPEED MOTOR OPERATION The 2-speed wheel motors in your Sys.III kit are shifted from full to half displacement through the use of a Displacement control valve. This valve is mounted near the Equa-Trac II valve and is operated with charge pressure from the Equa-Trac II valve and by an additional toggle switch mounted in your cab. The toggle switch will energize the solenoid on the displacement control valve and supply charge pressure to the wheel motors. The charge pressure shifts a spool in the wheel motors and shifts the motors to half displacement. Operating the motors at half displacement will give you less pulling power but more speed than operating at full displacement. REMOVAL OF EXISTING COMPONENTS Park the cotton picker in a clean working area. Apply the PARK or EMERGENCY BRAKE and block the front wheels to prevent the machine from rolling. Using a suitable lift device, jack or hoist, raise the rear of the machine so that the rear tires are several inches off the ground. Place the jack stands securely under the rear frame of the machine. Remove the rear tires. Disconnect and remove the steering tie rod assembly from the wheel ends. Disconnect the hydraulic hoses from the steering cylinders and place aside for later re-connection. Plug the hose ends. NOTE: Before disconnecting the hoses, mark the hoses and connectors to aid in correct reconnection later. If the hose connections are switched, the rear drive wheels will steer opposite the steering wheel. Disconnect the steering cylinders from the wheel ends and the axle steering brackets. Remove the steering cylinder ends and replace with the larger supplied cylinder ends. Remove the original stub axle mounting bolts and save for later use. Remove the stub axles and the steering cylinder anchor plates. NOTE: Always refer to the John Deere TECHNICAL MANUAL when disassembling any JD components. Remove the front and middle plant shields from both sides of the machine for installation access. 2

5 INSTALLING MUD HOG COMPONENTS Your Mud Hog kit will adjust from either 82 to 90" tread center or from 94 to 118" tread center. NOTE: Tread center is measured from center of tire to center of opposite tire at the ground. Follow the instructions pertaining to your particular kit. INSTALLING STUB AXLE AND WHEEL DRIVE ASSEMBLIES CAUTION: Wheel drive assemblies are extremely heavy. Use a lift device of adequate capacity. Cylinder Anchor (94-118") Cylinder Anchor (82-90") TREAD CENTER 82" 86" 90" 94" 98" 102" 106" 110" 114" 118" STUB AXLE BOLT LOCATION 1,4,5,7 2,5,6,8 3,6,7,9 10,17,18,20,23 11,18,19,21,24 12,19,20,22,25 13,20,21,23,26 10,14,17,18,21,22,24 11,15,18,19,22,23,25 12,16,19,20,23,24,26 Figure 1. 3 CYLINDER ANCHOR BOLT LOCATION 1,4,5,7 2,5,6,8 3,6,7,9 12,15,19,21,22 12,15,20,22,23 13,14,15,21,23 12,14,15,19,22 12,15,19,20,23 12,13,14,20,21 13,14,15,21,22

6 8" 7 1/2" 7" 82" 86" 90" Figure " TREAD CENTERS: Mount the Mud Hog stub axle and wheel drive assemblies to the rear side of the axle center section as done with the original axles. Align the holes in the stub axle and the cylinder anchor with the center section. Use the holes specified for desired tread center and mount the stub axle and cylinder anchor to the center section. See Figures 1 & 2. Use the original mounting bolts to secure the Mud Hog components. Figure 2 shows where to use the different length bolts in the center section. Torque the bolts to the original specification. 4

7 8" 7 1/2" 7" 94" 98" 102" 106" Figure " TREAD CENTERS: Mount the Mud Hog stub axle and wheel drive assemblies to the rear side of the axle center section as done with the original axles. Align the holes in the stub axle and the center section. Use the holes specified for desired tread center and mount the stub axle to the center section. See Figures 1 & 3. Use the original mounting bolts to secure the Mud Hog components. Figure 3 shows where to use the different length bolts in the center section. NOTE: 9960 machines have one less bolt hole per side on the center section than 9965 machines. Therefore, bolt locations 23, 24, 25 and 26 are not used in " tread centers. Mount cylinder anchors as shown in Figure 3. Install five 7/8 x 2 bolts per anchor in holes designated in Figure 1. Torque the bolts to the original specification. 5

8 5" 8" 7 1/2" 8" 5" 110" 114" " TREAD CENTERS: 118" Figure 4. Mount the Mud Hog stub axle and wheel drive assemblies to the rear side of the axle center section as done with the original axles. Use the holes specified for desired tread center and mount the stub axle to the center section. See Figure 1. Replace the stabilizer cylinder plate on the left hand side with the supplied L.H. sta-bar bracket. Use the original mounting bolts and the supplied 7/8 x 5 bolts and 7/8 washers to secure the sta-bar bracket and stub axle to the center section. Put the supplied R.H. sta-bar bracket on the right hand side. Use the supplied 7/8 x 8 and 7/8 x 5 bolts and 7/8 washers to secure the stub axle and sta-bar bracket to the center section. Figure 4 shows where to use the different length bolts in the center section. Mount cylinder anchors as shown in Figure 4. Install five 7/8 x 2 bolts per anchor in holes designated in Figure 1. Torque the bolts to the original specification. CAUTION: Interference may occur at these tread centers between the tire and the basket rail when driving the machine with basket lowered. The basket should not be lowered completely when driving the machine. 6

9 REMOUNTING STEERING CYLINDERS Remount the axle anchor end of the steering cylinders into the tapered holes of the Mud Hog steering cylinder bracket. The clamp on the anchor end of the cylinder may need to be positioned properly to keep it from hitting the anchor while turning. Mount the rod end of the cylinders into the cylinder brackets on the wheel drives. Use provided 5/8 hardened whashers under slotted hex nut if required. Secure the tapered studs with the original slotted hex nuts. Torque the nuts to specification and insert cotter pins. See Figure 19. Re-connect the steering cylinder hydraulic hoses to their original positions and torque hose ends to specification. INSTALLING EQUA-TRAC II (E-T II) VALVE Install the supplied adapters (12 ORB-M x 12 JIC-M for 9960 or 12 ORB-M x 12 ORS-M for 9965) on the valve as shown in Figure 5. Torque fittings to specification. Using two supplied 3/8 x 1 1/2 bolts and lockwashers, mount Equa-Trac II valve onto valve bracket. See Figure 7. Using an original 1/2" bolt on the oil pan and an original 3/4" bolt that goes through the frame, install the supplied valve support brackets on both sides. See Figures 6 & 7. Using two supplied 3/8 x 1 bolts and locknuts, install the valve bracket and valve into holes in valve support brackets. Install supplied bulkhead tee into valve bracket. See Figure 7. Torque all bolts to specification. NOTE: Valve shield will be installed after hoses are connected to valve. SYS.III - MOUNTING DISPLACEMENT CONTROL VALVE Mount displacement control valve onto valve mounting bracket using supplied 3/8 x 1 1/4 bolts and lockwashers. Put ground wire with 3/8 ring terminal onto one of the bolts. Torque bolts to specification. See Figure 7. NOTE: Displacement control valve is only included in Sys.III kits. Reverse Forward Figure 5. Case Drain Connection 3/4" Bolt 1/2" Bolt Figure 6. 7

10 L.H. Valve Support 3/4" Original Bolt 1/2" Original Bolt Valve Bracket Displacement Control Valve (Sys.III only) R.H. Valve Support Bracket Bulkhead Tee Equa-Trac II Valve Valve Shield Figure 7. 8

11 Manifold Adapter Block Reverse Forward Figure 8. Hydrostatic Motor Figure 9. MOUNTING MANIFOLD ADAPTER BLOCK NOTE: The hydrostatic system oil may be drained at this time. Many of the following procedures require removal and replacement of various hydraulic fittings and connectors in the hydrostatic system. Oil within the system will leak from these connections as the procedures are performed. Refer to John Deere specifications and recommended procedures for servicing the hydrostatic system. Always keep in mind cleanliness and safety precautions. Install the supplied 90 degree fittings (12 ORB-M X 12 JIC-M for 9960 or 12 ORB-M x 12 ORS-M for 9965) into the ports of the manifold adapter block and torque to specification. See Figure 8. Locate hydrostatic motor on right hand side of machine behind front tire. See Figure 9. Remove all hydraulic hoses attached to the relief manifold block on the hydrostatic motor. CARE- FULLY remove the relief manifold block from the hydrostatic motor. Do NOT drop or abusively handle manifold block. The mated sealing surface must NOT be warped or scratched. Replace the sealing O-Rings in the relief manifold block with new O-Rings and back-up washers supplied in the kit. Apply grease to hold the O-Rings in place. Slide the four supplied 3/8 x 5 1/2" bolts through the mounting holes of the relief manifold block. Secure the entire assembly to the hydrostatic motor CAREFULLY and firmly hold the manifold block against the hydrostatic motor during the assembly to keep the O-Rings in position. See Figure 10. NOTE: If O-Rings slip out of place, RESULTING oil leaks must be repaired. Reconnect all fluid lines to the relief manifold block. Torque the bolts to specification. Manifold Block Relief Manifold Block Hydrostatic Motor Figure 10. 9

12 MOUNTING HOSE GUIDES Install supplied right and left hand hose guides on top of center section using supplied 3/8 x 1" bolts and lockwashers. Mount into existing tapped holes on top of center section. See Figures 11 & 12. Install supplied long hose guides onto right and left hand hose guides using supplied 3/8 x 1" bolts and locknuts. See Figure 12. Torque bolts to specification. Tapped Holes Figure 11. L.H. Hose Guide Hose Routing Long Hose Guide L.H. Hose Guide Figure

13 CONNECTING AND ROUTING HYDRAULIC HOSES IMPORTANT: Torque the hose end fittings to specification ONLY after both ends are connected. When tightening the hose fittings do NOT allow the hose to twist. A twisted hose contributes to hose failure. Over-tightening can damage the fittings. Refer to the torque specifications at the front of this manual. A. EQUA-TRAC II VALVE TO WHEEL DRIVES HOSE ROUTING SYS.II " TREAD CENTERS: Match together the straight ends of two 69" high pressure hoses with the 45 degree end of a 79" drain hose and the 3/8 straight end of a 71" flush hose. This set of hoses is to be installed on the right hand side. Match together the straight ends of the two remaining 69" high pressure hoses with the 45 degree end of the 73" drain hose and the 3/8 straight end of the remaining 71" flush hose. This set of hoses is to be installed on the left hand side. Route hoses through mounted hose guides. The straight ends of the high pressure hoses go toward the wheel motors. SYS.III " TREAD CENTERS: Match together the straight ends of two 69" high pressure hoses, the 45 degree end of a 79" drain hose, the 3/8 straight end of a 71" flush hose and the 90 degree end of one 82" 2-speed hose (1/4" I.D.). This set of hoses is to be installed on the right hand side. Match together the straight ends of the two remaining 69" high pressure hoses, the 45 degree end of the 73" drain hose, the 3/8 straight end of the remaining 71" flush hose and the 90 degree end of the remaining 82" 2-speed hose. This set of hoses is to be installed on the left hand side. Route hoses through mounted hose guides. The straight ends of the high pressure hoses go toward the wheel motors. SYS.II " TREAD CENTERS: Match together the straight ends of two 83" high pressure hoses with the 45 degree end of a 92" drain hose and the 3/8 straight end of a 85" flush hose. This set of hoses is to be installed on the right hand side. Match together the straight ends of the two remaining 83" high pressure hoses with the 45 degree end of the 88" drain hose and the 3/8 straight end of the remaining 85" flush hose. This set of hoses is to be installed on the left hand side. Route hoses through mounted hose guides. The straight ends of the high pressure hoses go toward the wheel motors. SYS.III " TREAD CENTERS: Match together the straight ends of two 83" high pressure hoses, the 45 degree end of a 92" drain hose, the 3/8 straight end of a 85" flush hose and the 90 degree end of one 96" 2-speed hose (1/4" I.D.). This set of hoses is to be installed on the right hand side. Match together the straight ends of the two remaining 83" high pressure hoses, the 45 degree end of the 88" drain hose, the 3/8 straight end of the remaining 85" flush hose and the 90 degree end of the remaining 96" 2-speed hose. This set of hoses is to be installed on the left hand side. Route hoses through mounted hose guides. The straight ends of the high pressure hoses go toward the wheel motors. 11

14 B. EQUA-TRAC II VALVE TO WHEEL DRIVES HOSE CONNECTIONS Connect hoses to wheel motors and valves as shown in Figures 13A (Sys.II) & 13B (Sys.III). NOTE: On Sys. III units the forward and reverse connections are opposite the normal positions on the R.H. motor. Connect one end of the high pressure hose to motor tube labeled A. Connect the other end of the same hose to the fitting on the valve labeled A. Connect other hoses in this manner. Connect hoses from the right hand wheel drive to the right hand side of the valve. Connect hoses from the left hand wheel drive to the left hand side of the valve. NOTE: The case drain hose from the right hand wheel drive must cross under the bottom of the E-T II valve to the bottom fitting on the left hand side. NOTE: Install a supplied 08 JIC elbow to the drain fitting, labeled C, on the left hand wheel motor (Sys.II only) before connecting the 45 degree hose end. Sys.III- Using one of the 18" hoses, connect the bottom elbow (stamped T on displacement valve) to reducer at E-T II valve drain fittings, C. Using the other 18" hose, connect the rear elbow (stamped P) to 1/4" tee on E-T II valve. See Figure 13B. Torque all hose ends and fittings at E-T II valve and wheel drives to specification. Turn wheel drives from side to side. Check that hoses do NOT kink, twist, or bind. Make any necessary adjustments to fittings. L.H. R.H. Connect supplied 08 JIC elbow to fitting "C" on the left hand motor before connecting the drain hose (Sys.II only). Motors Valve A - Forward High Pressure 1/2" Str. 1/2" 45 Deg. B - Reverse High Pressure 1/2" Str. 1/2" 45 Deg. C - Case Drain 1/2" 45 Deg. 1/2" Str. D - Motor Flush 3/8" Str. 1/2" Str. Figure 13A. 12 Hose Ends

15 L.H. R.H. FRONT REAR Hose Ends Motors Valve A - Forward High Pressure 1/2" Str. 1/2" 45 Deg. B - Reverse High Pressure 1/2" Str. 1/2" 45 Deg. C - Case Drain 1/2" 45 Deg. 1/2" Str. D - Motor Flush 3/8" Str. 1/2" Str. E - Displacement Control 1/4" 90 Deg. 1/4" Str. Figure 13B. 13

16 Cooler & Reservoir Door Hose Figure 14. Figure 15. C. CASE DRAIN AND MOTOR FLUSH HOSE CONNECTIONS 9960 ONLY Locate the oil cooler and reservoir. See Figure 14. Locate the hose supplying cool oil to the reservoir. See Figure 15. Cut off one end of this hose. Replace cut-off end with supplied 30" hose. Install the flushing supply tee, case drain tee, and the check valve between the original cooler hose and the 30" supplied hose. See Figure 16. Make sure that the arrow on the check valve is pointing from the flush tee to the case drain tee (Toward the reservoir). Replace the small square door on the floor between the reservoir and the cooler with supplied door that has two round holes in it. See Figure 15. Install the two supplied 7/8 grommets in the holes. Remove bolt & latch assembly from original door and install onto supplied door. Route the two 84" flush & drain hoses through these holes up to the flush tee and drain tee. Connect the two hoses to the flushing supply and case drain tees using the hose clamps provided. Connect the case drain hose to the top 1/2" tee on the E-T II valve and connect the flush hose to the bulkhead tee installed on the valve bracket. See Figures 13 & 16. Clamp Drain Tee Flush Tee Clamp 1/2" Drain Hose to Valve 3/4" Hose to Reservoir Check Valve 1/2" Flush Hose to Bulkhead Tee 3/4" Hose from Cooler (30" supplied) Figure

17 9965/70 ONLY Locate the oil cooler and reservoir. See Figure 14. Locate the hose supplying oil from the cooler to the reservoir. See Figure 15. Replace this hose with supplied tube, 30" hose, two 12 ORS tees, two reducers and check valve. See Figure 17. Make sure that the arrow on the check valve is pointing from the flush tee to the case drain tee (Toward the reservoir). Connect the two 42" hoses with straight ends on both ends to the flush and drain tees and to the supplied 08 ORS bulkhead adapters. Install the two bulkhead adapters,with two supplied 7/8 hardened washers as spacers, into existing holes located on the right hand side of the cooler in the front wall of the cooler and reservoir compartment. See Figure 17. Connect the two 48" hoses with straight and 90 degree ends to the bulkhead adapters and to the E-T II valve and bulkhead tee at the valve. Connect the straight ends to the bulkhead adapters. Trace the hose coming from the flush tee (closest to the cooler) through the bulkhead adapter down to the bulkhead tee at the valve and connect the 90 degree end. Connect the other hose with the 90 degree end to the top 08 JIC tee on the E-T II valve. NOTE: This hose should trace back to the drain tee (closest to the reservoir). See Figures 13 & 17. Bulkhead Adapters 3/4" Hose from Cooler (30" supplied) Flush Tee Reducer 1/2" Flush Hose to Bulkhead Tee Check Valve 1/2" Drain Hose to Valve Reducer Drain Tee 3/4" Tube to Reservoir Figure

18 Hose Clamp Cordura Figure 18. D. MANIFOLD BLOCK TO EQUA-TRAC II HOSE ROUTING Match together the two 84" long (3/4" ID) hoses. Slide the supplied 60" long cordura (nylon) sleeve over these hoses. Route the straight ends of the sleeved hoses to the right hand side of the machine along the side of the oil pan toward the manifold adapter block. Use the large coated hose clamp to secure hoses to bracket in front of the front engine mount. Replace original bolt with provided 3/8 x 1 1/4 bolt. NOTE: Position cordura sleeve at points of contact to prevent hose abrasion. Do not allow hoses to come in contact with oil pan. See Figure 18. E. MANIFOLD BLOCK TO EQUA-TRAC II VALVE HOSE CONNECTIONS Connect the straight end of one of the 84" long hoses to the top (reverse) fitting in the manifold adapter block. Connect the remaining 84" long hose to the bottom (forward) fitting in the manifold adapter block. Do NOT tighten hose end fittings at this time. See Figure 8. Connect the hose coming from the bottom (forward) fitting in the manifold adapter block to the forward fitting on the E-T II valve (above solenoid). Connect the other hose to the reverse fitting on the valve. See Figure 5. Be sure that the hoses are routed smoothly and are not twisted. Torque hose fittings at the E-T II valve and the manifold adapter block to specification. MOUNTING VALVE SHIELD Mount valve shield to valve support brackets using supplied 3/8 x 1 bolts and locknuts. See Figure 7. 16

19 Outer Tie Rod Inner Tie Rod 1/2 x 3 1/2 Bolts, Nuts Clamp Halves & Spacers Steering Cylinder 118" Tread Center Shown Figure 19. MOUNTING TIE-ROD Slide the small diameter tie rod extension into the large diameter tie rod extension. Adjust the tie rod to the correct length for your tread center by sliding the tubes together. Install two 1/2 x 3 1/2 bolts with clamp half, spacer and lock nut thru tie rod tubes. Torque to specification. Mount the tapered studs of the tie rod ends through the bottom of the tapered holes; adjust the tie rod ends if necessary in order for the tapered studs to fit into the tapered holes. Attempt to maintain equal amounts of exposed thread on both tie rod ends. Install the slotted hex nuts. Torque the slotted hex nuts to ft.lbs. and insert the cotter pins. See Figure 19. MOUNTING WHEELS/ADJUSTING TOE-IN Mount the wheels onto the wheel motor hub flanges with the center of the wheel in-board of the wheel motor flange. NOTE: Installing the wheels "dished-out" with the center of the wheel outside of the mounting flange on the motors will VOID your warranty. Install the lug nuts and torque to proper specification. NOTE: Older axles, made in 2002 or earlier have a 2-piece nut. The torque specification for this type of nut is 369 ft.lbs. During 2002, the style of nut changed to a 1-piece nut and the torque specification for this type of nut is 442 ft.lbs. Place both wheels in a straight ahead position. Proper toe in should be 1/4" to 3/8" closer together in the front than in the rear. Measure the toe-in from the center of the tire to center of tire, preferably at the height of the wheel center; at the same height from the ground in the front and in the rear. Adjust the toe-in by twisting the tie-rod assembly. Adjust the tie-rod until the proper toe-in specifications are achieved. NOTE: The two 1/2" bolts going through the tie-rod should be kept horizontal as shown in Figure 19. Tighten the tie rod jam nuts. 17

20 MOUNTING ELECTRICAL COMPONENTS 9960 ONLY Install the supplied 1/2" rubber grommet into the large hole on the supplied actuator. Bolt the actuator and plate to the linkage arm using supplied 1/4 x 1" bolts and locknuts as shown in Figure 21. Linkage Arm Existing Holes Transmission Cover Actuator Plate Grommet Figure

21 Transmission Case Cover (L.H. side) Figure 22. Mount the wobble switch and bracket assembly to the existing holes in the boss on the lower left hand side of the transmission case cover (left hand side of the machine). Use the two supplied M8 x 20mm bolts and 5/16 lock washers to mount the switch and bracket assembly. See Figure 22. The wobble switch should be mounted so that the switch stick is in a straight out neutral position when the transmission is in neutral. Check for proper movement of the wobble switch stick when the gear shift lever is shifted into 1st, 2nd, and 3rd gear. Adjustment of the wobble switch and/or the actuator may be necessary to get the switch stick straight in neutral. Install the toggle switch and fuse holder in the control panel next to the hydrostat lever. Drill holes if necessary. Apply the supplied ON/OFF toggle switch and fuse holder decals. See Figure 23. Connect one wire lead from the fuse holder to a 12 VOLT source that is hot when the ignition switch is ON. Connect the other lead from the fuse holder to one of the male terminals of the toggle switch. Refer to the wiring diagram. See Figure 24. Route the wire lead with the female connector from the wobble switch up to the toggle switch in the cab; connect to the remaining male terminal of the switch. Route and connect the other wire lead with the ring terminal from the wobble switch to the threaded terminal post on the solenoid valve located at the Equa-Trac II valve. Fuse Toggle Switch Valve Solenoid Toggle Switch Fuse Holder Ignition or "Hot Source" Wobble Switch Figure 23. Figure

22 Figure /70 ONLY Install supplied rocker switch into space provided for it in R.H. console in cab of cotton picker. Put supplied label on rocker switch. Remove the door on the side of the console facing the inside of the cab. Above the door there should be a drawing similar to the one shown in Figure 25. Install the supplied fuse and relay assembly in spaces designated. Locate wiring harness on R.H. side of cotton picker, just ahead of the Equa-Trac II valve, behind the frame rail. See Figure 26. Connect supplied wire assembly to orange wire #144 in wiring harness and to the threaded post on the solenoid valve located on the Equa-Trac II valve. Sys.III - Install supplied toggle switch and fuse holder assembly in the control panel near the rocker switch for the MUD-HOG. Drill holes if necessary. Apply the supplied ON/ OFF toggle switch and fuse holder decals. Connect one wire lead from the fuse holder to a 12 VOLT source that is "hot" when the ignition switch is ON. Connect the other lead from the fuse holder to one of the male terminals of the toggle switch. Using supplied bulk wire and female connectors, connect the toggle switch to the displacement control valve. Route the wire from displacement control valve to the toggle switch. Use supplied female connectors to connect wire to male connector on displacement control valve wire and toggle switch. 20

23 Hose Clamp (Both Sides) Figure 26. Wiring Harness Connection Re-install the front and middle plant shields on both sides of the machine. Use two remaining coated hose clamps to hold hoses running from wheel motors to valve. Install one clamp on each side of machine using original bolt on plant shield between rear axle and valve. See Figure 26. NOTE: Use the provided tie straps as necessary to secure wires when routing them to the cab and the solenoid. Route the wires clear from moving parts. ADJUSTING STEERING STOPS: PRE-START PROCEDURES Locate steering stop bolts on the top of each stub axle and wheel drive assembly. Loosen the jam nuts and screw stop bolts completely in. Turn the steering wheel to the right until the tie rod ear hits the stop bolt. Check to make sure the tires do not interfere with side panels or the frame of the ference is eliminated. Return wheel to a straight ahead position. See Figure 27. Tie Rod Ear Stop Bolt and Jam Nut Figure

24 Lug nut torque Grease decal Axle bolt torque Grease decal Figure 28. Lug nut torque Put supplied grease decals and torque decals on axle as shown in Figure 28. Also put grease decals on tie rod ends. Check that all bolts, nuts and hydraulic connections are torqued to specification. See torque specifications at front of manual. Check that all hoses and wires are properly routed, free and clear of any moving parts and secured properly. Check wiring. Turn ignition switch "ON". Do not start engine. Operate Mud Hog switch "ON" and "OFF". Listen for a soft clicking sound at the Equa-Trac II valve solenoid to insure proper wiring function. Sys.III Turn ignition switch "ON". Do not start engine. Operate displacement control switch "ON" and "OFF". Listen for a soft clicking sound at the displacement control valve to insure proper wiring function. Fill hydrostatic reservoir. Follow JD specifications and recommendations concerning hydrostatic fluid and the servicing of filters. SEE START-UP PROCEDURE AT END OF TROUBLESHOOTING MANUAL. 22

25 4WD Mud Hog Vinyl Decal Application Instructions To apply your decal, please follow the instructions below: 1. Clean area above rear wheel on ladder side of machine to remove dirt and grime. 2. Without removing the paper backing, position decal on surface exactly where you want it. 3. Once the decal is in position, place a piece of masking tape along the top edge to hold the decal in place. 4. The decal should be sitting on the surface like a flap. Lift up the decal and remove the paper backing. 5. With the backing paper completely removed from the decal & transfer tape, gently lower the decal with the transfer tape back down to the surface and rub it down lightly with your hand. 6. The transfer tape should still be on the side of the decal facing you. This allows you to rub the decal without scratching or damaging the decal. Take a squeegee or credit card and firmly rub the transfer tape and thus the decal until it is firmly adhered to the surface. 7. Finally, peel off the transfer tape and masking tape gently. The decal will adhere to the surface much more aggressively than the transfer tape. The transfer tape should lift easily leaving behind no sticky residue. 8. Your decal installation is complete. If there are bubbles present under the decal that cannot be removed by working them to edge, a small needle or pin can be used to puncture the bubble and remove the air. A small pin hole will not be seen after the air bubble has been worked out.

26 LIMITED WARRANTY Tuthill Drive Systems ( Tuthill ) warrants Mud Hog drive systems and components to be free from defects in material and workmanship under normal use and service as shown in the chart below from the date of shipment from Tuthill. Installed By: Warranty Period Tuthill Drive Systems Mud Hog 24 months parts and 12 months labor for the Mud Hog kit & Installation. Authorized Mud Hog Dealer 24 months parts and 12 months labor for the Mud Hog kit. Note: Any defects resulting from installation errors are covered by the installer. Warranty period start date is determined by ship date from Tuthill Drive Systems. Normal use and service means that the product will be installed by a qualified mechanic, operated, inspected and maintained in accordance with the applicable Mud Hog manual or instructions and any applicable vehicle manufacturer s manual or instructions. Tuthill is not liable for any printing errors contained within manuals. THE ABOVE WARRANTY IS EXCLUSIVE. TUTHILL MAKES NO OTHER REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. No agent, distributor, dealer or employee of Tuthill has authority to extend the scope of this warranty. This warranty applies only to products which are sold and used only in the United States, Canada and Mexico. [Tuthill does not itself warrant components which bear the name or trademark of another manufacturer. Any warranty or remedy for such parts is limited to the extent of any warranty provided by the manufacturer to Tuthill.] No warranty applies in the event of replacement of parts with parts not obtained from or approved by Tuthill which do not meet Tuthill quality and performance specifications, improper installation, maintenance, repair, misuse or abuse, or unauthorized alteration or modification. Wheel motor warranty will be denied if the motor is disassembled and or serviced by anyone other than an authorized Tuthill service center within the warranty period. Tuthill reserves the right to make changes and improvements in design, specifications or instructions without notice and without obligation to provide or to substitute new design modifications for those Mud Hog systems or components already in service. Tuthill will at its option refund the purchase price of, or repair or replace without charge for parts, any Mud Hog product determined by Tuthill to be defective in material or workmanship during the applicable warranty period. Labor allowance, if applicable, will be determined in accordance with Tuthill s warranty labor rate and time allowances established from time to time. These remedies are exclusive. In no event shall Tuthill s liability exceed the purchase price for the Mud Hog product when sold by Tuthill to the first buyer. Tuthill shall not be liable for any incidental or consequential damage or expense resulting from any product defect, including but not limited to loss of profits, loss of use of equipment, increased costs or other expenses. This warranty shall become effective only when the Warranty Certificate has been returned to Tuthill and validated by same. INSTALLER AND OWNER RESPONSIBILITIES The installer is responsible for installing the product according to Tuthill s approved procedures, for providing a copy of Tuthill s warranty and installation/parts manual to the owner, and for advising the owner of proper use, service, and maintenance required for the product. The owner is responsible for operation, inspecting and maintaining the product according to the instructions in the installation/parts manual and any applicable vehicle manufacturer s owner s manual, and for properly instructing all operators and maintenance personnel. ADJUSTMENTS When adjustment is sought under this warranty, a claim should be made as follows: A. Tuthill must be notified in writing promptly upon discovery of a claimed defect. B. If the product was installed by the vehicle manufacturer (or it s dealer), follow the manufacturer s procedures for warranty claims; or If the product was purchased from Tuthill through a distributor of Mud Hog products, have the distributor write or phone the Tuthill Customer Service Department and ask for a Returned Goods Authorization Number (RGA#). A warranty claim form will be submitted with information including: The RGA#, Tuthill axle serial #, retail sales date, machine hours and a description of the failure. C. Components requested by Tuthill must be returned freight prepaid and accompanied by a properly completed warranty claim form. Tuthill will specify the ship-to address at time of return approval W. 800 S., Brookston, IN 47923, Tel: / Fax: tdswebinquiries@tuthill.com Web: